JP6162234B2 - Lens precursor having a characteristic part for manufacturing an ophthalmic lens - Google Patents

Description

  The present invention describes a lens precursor device having one or more lens precursor features that can be useful in the manufacture of ophthalmic lenses. More specifically, the lens precursor is a composite object including a lens precursor mold and a fluid lens reactive medium that contacts the lens precursor mold, and the lens precursor is an ophthalmic lens formed by a free shaping method. Can be useful in the manufacture of.

  Currently, ophthalmic lenses are often made by casting, in which a reactive monomer material is deposited in a cavity defined between the optical surfaces of opposing mold parts. In order to prepare a lens using such a mold part, an uncured hydrogel lens formulation is placed between a plastic disposable front curve mold part and a plastic disposable back curve mold part.

  The front curve mold part and the back curve mold part are typically molded via an injection molding technique in which the molten plastic is highly machined with at least one optical quality surface. It is pushed into a steel molding tool.

  The front curve mold part and the back curve mold part are joined to form a lens according to the desired lens parameters. Thereafter, the lens formulation is cured, for example, by exposure to heat and light, to form a lens. After curing, the mold parts are separated and the lens is removed from the mold for hydration and packaging. However, the cast molding process and the nature of the instrument make it difficult to form a custom lens for a specific patient eye or a specific application.

  Accordingly, the previous description by the inventor describes a method and apparatus for the formation of customized lenses through the use of freeform techniques. An important aspect of these new technologies is that the lens is produced by a freeform process, that is, one of the two surfaces of the lens requires the use of cast molding, a lathe, or other molding tool. Without being formed by a free-formation method.

  The free-form surface and base can include a flowable lens s-reactive medium that is included in the free-form surface at some point during formation. This combination results in a device sometimes referred to as a lens precursor. Immobilizing radiation treatment and hydration treatment can usually be used to convert lens precursors into ophthalmic lenses.

  Some of the free-form lenses produced in this manner require different methods and / or structural features to control all or part of the flowable lens reactive medium contained in the lens precursor. It may be. By controlling some of all of the flowable lens reactive media, physical and / or optical parameters of the lens design can be generated. Its new methods and features are the subject of the present invention.

  The present invention is directed to a lens precursor and a method of forming the lens precursor for the manufacture of an ophthalmic lens. More specifically, a lens precursor that can comprise one or more lens precursor features used in at least a plurality of portions of the flowable lens reactive medium portion of the lens precursor as part of the base structure.

  Some aspects of the present invention are different for iterating, such as generating a DMD display and DMD file, for example, to produce a lens precursor that can include one or more lens precursor features. Including methods and apparatus. In general, the applied patient and product data can be collected and used to generate a standard or custom design. The desired product design or lens precursor design can comprise one or both of a lens precursor feature and a flowable lens reactive media surface.

  The desired product lens design can be generated from the lens precursor design, thickness map, and associated files. Separate thickness maps and associated files can be used as stand-alone files or in combination with other thickness maps. For example, a DMD display may be generated from a lens precursor thickness map and associated file, a lens design thickness map and associated file, DMD subsequence (s), or other method and used to manufacture a lens precursor. it can.

  The manufactured lens precursor can be compared to the thickness map and associated files to determine suitability for the desired product design. If the manufactured product cannot or does not meet the desired requirements, a DMD iterative display can be generated and modified to produce a lens precursor that can more closely approximate the desired product design.

  The following is a non-exhaustive list of exemplary embodiments of the invention that can be claimed or can be made.

Embodiment 1:
A lens precursor mold comprising a crosslinkable medium comprising a light absorbing component;
A first surface and a second surface, wherein the first surface includes a first crosslink density portion at least partially polymerized at or above the gel point. Two surfaces;
A second fluid surface having a crosslink density of the second cured product less than the gel point,
The first surface includes an at least partially polymerized phase feature that can act as a lens precursor type substructure, and at least a portion of the second surface is incorporated into an ophthalmic lens. An ophthalmic lens precursor.

  Embodiment 2: The phase feature includes one or more of a lens edge feature portion, a bump feature portion, a discharge channel feature portion, a volumator feature portion, a rake feature portion, and a stabilization zone feature portion. The ophthalmic lens precursor of embodiment 1 comprising.

  Embodiment 3: The ophthalmic lens precursor of embodiment 2, further comprising one or more of each of the one or more included phase feature (s) included.

  Embodiment 4: The ophthalmic lens precursor of embodiment 2, wherein each included feature includes one or more of a particular height, length, shape, and width.

  Embodiment 5: The ophthalmic lens precursor of embodiment 4, wherein the angular width of one or more of the included features can be continuous over 360 degrees of the lens precursor.

  Embodiment 6: An ophthalmic lens precursor according to embodiment 4, wherein the angular width of one or more of the included features is discontinuous and is generally present in a separate portion of the first surface. body.

  Embodiment 7: The ophthalmic lens precursor of embodiment 1, wherein the first surface further comprises a moat feature in one or more separate portions.

  Embodiment 8: The ophthalmic lens precursor of embodiment 1, further comprising a mark in one or both of the first surface and the second fluid surface.

  Embodiment 9: The ophthalmic lens precursor of embodiment 1, wherein at least a portion can be rotationally symmetric.

  Embodiment 10: The ophthalmic lens precursor of embodiment 1, wherein the shape of the lens precursor can be generally circular.

  Embodiment 11 The ophthalmic lens precursor of embodiment 1, wherein the shape of the lens precursor can be generally elliptical.

  Embodiment 12: One or more of the included feature parts can be mathematically described by one or more of the height, width, length, shape, and position of the feature parts. The ophthalmic lens precursor according to Embodiment 2.

  Embodiment 13: In an embodiment 2, one or more of the included features can be empirically obtained from one or more designs of lens precursor (s) or parts thereof. The ophthalmic lens precursor described.

  Embodiment 14: The ophthalmic lens precursor of embodiment 1, wherein the lens precursor can be further processed into an ophthalmic lens.

  Embodiment 15: The ophthalmic lens precursor of embodiment 14, wherein the processing includes stabilization of at least a portion of the second fluid surface.

  Embodiment 16: The processing solidifies at least a portion of the second fluid surface using actinic radiation to a crosslink density at least partially polymerized at or above the gel point. The ophthalmic lens precursor according to embodiment 14, further comprising:

  Embodiment 17: The ophthalmic lens precursor of embodiment 3, wherein one or more bump features are used to form at least a portion of a bifocal lens.

  Embodiment 18: An ophthalmic lens precursor according to embodiment 3, wherein one or more bump features are used to form at least a portion of a trifocal lens.

  Embodiment 19: An ophthalmic lens precursor according to embodiment 3, wherein one or more bump features are used to form at least a portion of a lenslet array.

  Embodiment 20: The ophthalmic lens precursor according to embodiment 1, wherein the lens precursor is formed by a free shaping method.

  Embodiment 21: The ophthalmic lens precursor according to embodiment 20, wherein the free shaping method includes a free shaping method for each voxel.

Embodiment 22:
A lens precursor mold comprising a crosslinkable medium comprising a light absorbing component;
A first surface and a second surface, wherein the first surface includes a first crosslink density portion at least partially polymerized at or above the gel point. Two surfaces;
A second fluid surface comprising a crosslink density of the second cured product below the gel point,
An ophthalmic lens, wherein the first surface comprises at least partially polymerized phase features that can be used to determine the optical magnification of a device used to incorporate the lens precursor into an ophthalmic lens. precursor.

  Embodiment 23: The phase feature includes one or more of a lens edge feature, a bump feature, a discharge channel feature, a volumeometer feature, a rake feature, and a stabilization zone feature. The ophthalmic lens precursor according to Form 22.

  Embodiment 24: The ophthalmic lens precursor of embodiment 22, further comprising one or more marks.

  Embodiment 25 The ophthalmic lens precursor of embodiment 22, wherein the one or more marks can be embedded in one or more of the phase features.

  Embodiment 26 The ophthalmic lens precursor of embodiment 22, wherein the one or more marks can be on one or more of the phase features.

Embodiment 27:
A lens precursor mold comprising a crosslinkable medium comprising a light absorbing component;
A first surface and a second surface, wherein the first surface includes a first crosslink density portion at least partially polymerized at or above the gel point. Two surfaces;
A second fluid surface comprising a crosslink density of the second cured product below the gel point,
The first surface can be used at least partially to align the lens precursor with one or more parts of a device used to incorporate the lens precursor into an ophthalmic lens. An ophthalmic lens precursor comprising a phase feature polymerized into.

  Embodiment 28: The phase feature includes one or more of a lens edge feature, a bump feature, a discharge channel feature, a volumeometer feature, a rake feature, and a stabilization zone feature. The ophthalmic lens precursor according to Form 27.

  Embodiment 29: The ophthalmic lens precursor of embodiment 27 further comprising one or more marks.

  Embodiment 30: The ophthalmic lens precursor of embodiment 27, wherein the one or more marks can be embedded in one or more of the phase features.

  Embodiment 31 The ophthalmic lens precursor of embodiment 27, wherein the one or more marks can be on one or more of the phase features.

Embodiment 32:
A lens precursor mold comprising a crosslinkable medium comprising a light absorbing component;
A first surface and a second surface, wherein the first surface includes a first crosslink density portion at least partially polymerized at or above the gel point. Two surfaces;
A second fluid surface comprising a crosslink density of the second cured product below the gel point,
An ophthalmic lens precursor, wherein the first surface includes at least partially polymerized phase features that can be used as a lens identifier after the lens precursor is incorporated into an ophthalmic lens.

  Embodiment 33: The ophthalmic lens precursor according to embodiment 32, wherein the lens identifier is used as an anti-counterfeit mark.

The foregoing and other features and advantages of the present invention will become apparent from the following more detailed description of the preferred embodiment of the invention, as illustrated in the accompanying drawings.
2 is a side view of an exemplary cross-sectional representation of a lens precursor mold in flat space. FIG. FIG. 6 is a side view of an exemplary cross-sectional view of a lens precursor with a single lens precursor feature of multiple types in a flat space. 2 is a side view of an exemplary cross-sectional representation of a lens precursor with single and multiple types of lens precursor features in a flat space. FIG. FIG. 2 is an exemplary side view of a lens precursor with single and multiple types of lens precursor features in addition to a moat feature in a flat space. FIG. 6 is a top view illustrating an exemplary non-circular lens precursor with single and multiple types of lens precursor features in addition to the drain channel features. 2 illustrates an example of an image display depicting a mark formed on a lens. Fig. 4 illustrates exemplary method steps that may be used to implement some embodiments of the invention. Fig. 4 illustrates additional method steps that may also be used to implement some embodiments of the invention. Fig. 4 illustrates further method steps that may also be used to implement some embodiments of the invention. FIG. 6 illustrates an exemplary screenshot depicting a cross-sectional view of a target file in a curved space, generated by a software program (s). Figure 4 illustrates sample data representing a portion of a thickness map generated by a software program (s). FIG. 6 illustrates an exemplary screenshot generated by software program (s) that can be used to generate and output desired optical and mechanical features and used to generate a target file. FIG. 7 is a schematic diagram of the example screenshot of FIG. Figure 3 illustrates a schematic diagram of an exemplary processor that can be used with some components of the present invention. FIG. 4 illustrates an exemplary top view and cross-sectional view of a lens precursor in a curved space. FIG. 3 illustrates an exemplary top view and a cross-sectional side view of a lens precursor in flat space depicting an exaggerated thickness profile. Illustrative representations of continuous surface single part designs in both flat and curved spaces are illustrated in top and side views. Illustrative representations of a discontinuous surface single part design in both flat and curved spaces are illustrated in top and side views. Illustrative representations of a continuous surface multi-part design in a curved space are illustrated in top and side views. Illustrative representations of a discontinuous surface multi-part design within a curved space are illustrated in top and side views. FIG. 6 illustrates sample data representing a portion of a DMD file generated by software program (s). formed using a DMD file that can be implemented in some embodiments of the present invention rotated 180 ° about the y-axis and rotated 45 ° counterclockwise in the (xy) plane. 1 illustrates an exemplary lens. FIG. 4 illustrates an exemplary lens formed using a DMD file that includes a circumferential discharge channel. FIG. 4 illustrates an exemplary lens formed using a DMD file that includes a circumferential discharge channel command with a modified edge curvature command segment. FIG. 6 illustrates a photograph of an exemplary non-rotationally symmetric lens including a lens edge curve and a flattened segment of an exit channel. FIG. 4 illustrates an exemplary representation of two cross-sections (45 ° and 135 °) of a target lens design in a flat space, a DMD display, and a measured lens precursor.

  The present invention provides a lens precursor that is used to produce an ophthalmic lens, wherein the lens precursor device generates a substructure that can control the properties / characteristics of the final ophthalmic lens. A series of phase features used may be provided. In the following sections, exemplary embodiments of the invention are described in more detail. While the description of both the preferred and alternative embodiments is detailed, it will be understood by those skilled in the art that these are only exemplary embodiments and variations, modifications, and alternatives may be apparent. Accordingly, it is understood that the exemplary embodiments do not limit the breadth of the underlying inventive aspects. Although the method steps described herein are listed in a logical order in this description, this order does not in any way limit the order in which they can be performed unless otherwise indicated. .

Glossary In the specification according to the present invention, various terms to which the following definitions apply can be used.
“Acceptance criteria”, as used herein, is a measurement of a manufactured ophthalmic lens, lens precursor mold or lens precursor to determine whether the product is acceptable for the intended purpose. Refers to a specific parameter range and threshold within the system that can be correlated to the measured parameters and values.

  “Bump (s) feature” as used herein is a cured reactive media lens precursor that is cured at or above the gel point, thereby producing a phase feature. Refers to the protrusion of The bumps are formed, for example, by reducing actinic radiation exposure at one or more voxel location (s) by reducing the exposure signal provided by the DMD instruction (s) at these locations. be able to. In a similar manner, the bump increases the actinic radiation exposure at one or more voxel location (s) by increasing the exposure signal provided by the DMD command (s) at these locations. Can also be formed. The bumps can be positioned within all or a plurality of parts of the optical zone and can assist in the formation of one or more lenslet arrays after curing of the separate parts thereof. Alternatively or additionally, the bumps can be formed in a predetermined area of the optical zone for the formation of a bifocal lens.

  A “catalog item”, as used herein, is a file, feature, component that can be stored temporarily or permanently, eg, in a library or database, and can be replayed for use. , Design, data, or descriptor.

  “Curved space” as used herein refers to a coordinate mapping space (eg, Cartesian, polar, spherical, etc.) from which the design curvature has not been removed. As an illustrative example of such, the ophthalmic lens may be formed on a back curve mold part. The lens can have a three-dimensional shape that is essentially associated with the three-dimensional shape of the mold part during inspection. When the cross sections of the present example lens in the curved space are depicted, the bottom of these cross sections bend to resemble the curvature of the mold part. In order to better elucidate the surface shape of the front side of the lens, the thickness of the material on the back curve surface may be increased in some procedures of cross-sectional depiction. In these cases, the cross section can still be described as being presented in a curved space.

  “Customized product” as used herein refers to a product that includes one or more parameters that may be available outside of customary or standard products and / or configuration items. Custom product parameters can enable spherical power, cylindrical power, and cylindrical axis (eg, -3.125D / -0.47D x 18 °) more precisely targeted than standard products. Also, customized settings can be associated with base curves, diameters, stabilization profiles, and thickness profiles based on specific product offerings and product applications.

  “Digital core break” as used herein refers to a series of products in which a limited subset of lens precursor features or control parameters remains the same. For example, in a lens “digital core break” group provided in different magnification and spherical ranges, the lens edge, stabilization zone feature, and volumeometer feature are the same for all low magnification correction ranges. be able to.

  “DMD control software” as used herein refers to software that systematically uses DMD files and DMD displays as desired. For example, the software can be used to enable the manufacture or post-processing of lens precursors with lens precursor features.

  A “DMD file” as used herein can be used to activate a mirror on a DMD, whereby a lens or lens precursor, or lens precursor mold or lens precursor feature (s). ) Refers to a group of instruction data points that at least partially enable manufacture. DMD files can have various formats, with (x, y, th) and (r, θ, th) being the most common, for example, “x” and “y” are the Cartesian of the DMD mirror The coordinate positions, “r” and “θ” are the polar coordinate positions of the DMD mirror, and “th” represents the thickness command that controls the DMD mirror state. A DMD file can contain data on a grid that is regularly or irregularly spaced.

  “DMD Iterative Display”, as used herein, can be used to control the activation of mirrors on the DMD, such as a lens, lens precursor, lens precursor type, or lens precursor feature. Refers to a group of time-based instruction data points that allow for the production of one or more. The DMD repeat display can be closer to the design object than the lens, lens precursor, or lens precursor feature (s) produced by the preceding DMD display and / or DMD subsequence. Or for the production of lens precursor feature (s). The DMD repeat display can include data on a grid that is regularly or irregularly spaced.

  “DMD display” as used herein, on an optical element formed from a DMD device to produce a lens or lens precursor, or lens precursor mold or lens precursor feature (s). Refers to a series of projection patterns arranged on a time basis. The DMD display may be subdivided into a number of DMD subsequences. DMD displays may have a variety of formats, with (x, y, t) and (r, θ, t) being the most common, eg “x” and “y” are DMD mirrors Cartesian coordinate positions, “r” and “θ” are polar coordinate positions of the DMD mirror, and “t” represents a time command to control the DMD mirror state. The DMD display can include data on a grid that is regularly or irregularly spaced.

  “DMD subsequence”, as used herein, refers to one or more portions of a DMD display in which one or more of the projection characteristics of the DMD display can be modified. The modifications to the array can include one or more of a distributed pattern, a radiation intensity level, a spectral region to project, a mirror bit split arrangement, a direction of the projected pattern, and a time order of the projected pattern.

  A “DMD” or digital micromirror device, as used herein, is a bistable spatial light modulator consisting of an array of movable micromirrors functionally implemented throughout a CMOS SRAM. . Each mirror is independently controlled by reading data into the memory cells under the mirror to guide reflected light and spatially map the pixels of the video data to the pixels on the display. The data electrostatically controls the tilt angle of the mirror in a binary system where the mirror state is either + X degrees (on) or -X degrees (off). Current devices can make X either 10 degrees or 12 degrees (nominal). The light reflected by the mounted mirror then passes through the projection lens and onto the screen. The light is reflected to create a dark field and define the black level floor of the image. The image is generated by gray scale modulation between on and off levels at a rate fast enough to be integrated by the observer. A DMD (digital micromirror device) may be a DLP projection system.

  An “exhaust channel”, as used herein, is a chemistry in which multiple voxel locations are reduced or increased by control command (s) in a manner similar to that described in the definition of bump feature. Refers to the phase feature of the lens precursor that can be generated by exposure to either or both of the radiation. The phase feature is when the flowable lens reactive medium flows across or away from all or at least a portion of the polymerized lens precursor, the lens precursor mold, or another other lens precursor feature (s). It may be of a shape that can allow one or more of the following to flow and settle on. The terrain features can include, for example, continuous or separate segmented elongated depressions within multiple portions of the lens precursor gelation. The discharge channels can be arranged in parallel and configured to allow flow of the flowable lens reactive medium across the lens precursor mold.

  “Manufacturing process conditions” as used herein refers to settings, conditions, methods, instruments, and processes used in the manufacture of one or more of a lens precursor, a lens precursor mold, and a lens. Point to.

  “Flat space”, as used herein, refers to a coordinate mapping space (eg, Cartesian, polar, spherical, etc.) that is considered to have the design curvature removed / flattened. As a specific example of such depiction, an exemplary ophthalmic lens may be formed on a back curve mold part. The present lens example can have a three-dimensional shape that is basically associated with the three-dimensional shape of the mold part during inspection. When the cross sections of the present example lens in flat space are depicted, the bottom of these cross sections can be “removed / flattened”, resulting in a curved back curve shape represented by a flat line. . In order to better elucidate the surface shape of the front side of the lens, the thickness of the material on the back curve surface, now “removed / flattened”, may be increased in some processes of cross-section drawing. is there. In these cases, the cross-section can still be described as being presented in a flat space.

  As used herein, “fluid lens reactive media”, sometimes referred to as “fluid lens reactive mixture” or “lens forming mixture”, is in its original form, reacted form, or partially reacted Refers to a reactive mixture, prepolymer mixture, or monomer mixture that is fluid in form and can be formed into a portion of an ophthalmic lens after further processing. Furthermore, the monomer mixture or prepolymer material can be cured and crosslinked, or crosslinked. The lens-forming mixture includes one or more additives such as UV blocking agents, dyes, photoinitiators or catalysts, and other additives that may be desired in ophthalmic lenses such as contacts or intraocular lenses. But you can.

  “Free-form” and “free-form” as used herein are reactive mixtures that are exposed to actinic radiation on a per voxel basis, with or without a fluid media layer. Refers to a surface formed by cross-linking and not formed by a casting mold, lathe, or laser cutting. A detailed description of the freeform method and apparatus can be found in US patent application Ser. No. 12 / 194,981 filed Aug. 20, 2008, US Patent Application No. 12 / 195,132 filed Aug. 20, 2008, European Patent Publication No. EP-A-2,178,695, European Patent Publication No. EP-A-2,228,202, European Patent Publication No. EP-A-2,228,201, European Patent Publication No. EP-A-2,178,694 and EP-A-2,391,500.

  “Higher order optical aberration (s)” as used herein refers to distortion (s) in an image formed by an optical system due to optical deviation. More specifically, the eye may include one or more symptoms known as spherical aberration (s), trefoil, coma, and pentafoil in the field of vision correction. .

  “Iterative manufacturing process” as used herein is a DMD iterative to produce a lens, lens precursor mold, or lens precursor that can be closer to the desired thickness map / object design than the previous work. Refers to a process that performs an iterative loop using one or both of indication (s) and modifications to manufacturing process conditions.

  “Repetitive loop”, as used herein, passes through the loop each time the lens, lens precursor, lens precursor mold, or lens precursor feature (s) fits the desired object rather than the previous work. One or a series of process steps, components, and / or conditions that can allow for the production of a lens or lens precursor, lens precursor mold, or lens precursor feature (s), as Point to.

  “Rake feature”, as used herein, refers to the phase feature of a lens precursor that is included in some lens precursor designs. The rake feature is similar to that described in the definition of the bump feature, and the control of the DMD command (s) reduces the number of voxel positions to one or both of the reduced or increased actinic radiation. It can be generated by exposure. Rake feature sites, sometimes referred to as “rake phase features”, are part of the cross-linked gelling portion of the lens precursor so as to accommodate a larger volume of the flowable lens reactive medium in relation to adjacent regions. A depression may be included.

  “Lens design” as used herein, when manufactured, power correction, acceptable lens compatibility (eg, corneal coverage and movement), and acceptable rotational safety of the lens. It refers to the desired lens shape, function, or both, that can provide functional properties including gender. Lens designs include, for example, geometric drawings, power profiles, shapes, features, and thicknesses in either a hydrated or unhydrated state, flat or curved space, 2D or 3D space. It can be represented by a non-limiting method. The lens design can include data associated with regularly or irregularly spaced grids.

  “Lens edge” as used herein refers to an edge defined around at least a portion of a lens precursor, lens precursor mold, or lens periphery that may include a flowable lens reactive medium. Refers to a phase feature that can be provided. The lens edge phase feature can either be continuous around the lens precursor or lens, or can be present in a separate non-contiguous zone. Such a lens edge can include a fence structure configured to accommodate a flowable lens reactive medium present within the outer periphery of the lens precursor mold.

  A “lens precursor feature”, also referred to as a “feature” or “phase feature,” as used herein, is a lens precursor-type substructure that can act as the basis for a lens precursor. Refers to the non-fluid part. The lens precursor feature can be defined empirically or mathematically described by control parameters including height, angular width, length, shape, and position. The features can be generated via DMD display instructions using a controlled vector of actinic radiation and can be incorporated into the ophthalmic lens after further processing. Examples of lens precursor features include one of a lens edge, a stabilization zone feature, a volumeometer feature, an optical zone, a moat feature, a discharge channel feature, a rake feature, and a bump feature. Or a plurality can be included.

  As used herein, a “lens precursor mold” is a non-flowable object having at least one optical quality surface that can be further processed and matched with that incorporated into an ophthalmic lens. Point to.

  “Lens precursor” as used herein is a composite object comprising a lens precursor mold and a flowable lens reactive medium in contact with the lens precursor mold, which may be rotationally symmetric or non-rotary symmetric. Means. For example, the flowable lens reactive medium may be formed in the process of generating a lens precursor mold within the volume of the reactive mixture. The lens precursor can be produced by separating the lens precursor mold and the flowable lens reactive medium from the volume of the reactive mixture used to produce the lens precursor mold. In addition, the lens precursor can be separated into different entities by either removing a certain amount of the flowable lens reactive medium or converting a specific amount of the flowable lens reactive medium into a non-flowable embedded material. Can be converted.

  “Lens” as used herein refers to any ophthalmic device that is in or on the eye. These devices may provide optical correction or may be cosmetic. For example, the term lens refers to contact lenses, intraocular lenses, overlay lenses, ophthalmic inserts, optical inserts, or other similar appliances whose vision is corrected or altered, or the physiology of the eye without disturbing vision. Can refer to a device that is expanded (eg, iris colored). The lenses according to the present invention can be soft contact lenses made from silicone elastomers or hydrogels, including but not limited to silicone hydrogels, and fluorohydrogels.

  “Lower order optical aberration (s)” as used herein refers to distortion (s) in an image formed by an optical system due to optical deviation. More specifically, one or more symptoms known in the field of vision correction are corrected by adjusting one or more of spherical power, cylindrical power, and cylindrical axis in the eye. Can be included.

  As used herein, “minimum energy surface”, sometimes referred to as “MES”, refers to a surface produced by a flowable lens reactive medium formed on a lens precursor feature. This can be in a minimum energy state. The minimum energy surface can be a smooth and continuous surface of the lens precursor feature or a smooth separate segment.

  A “moat”, as used herein, can be formed using a fixed value in a DMD display in one or more regions, and is a lens precursor that is lower in height than the surrounding features. Refers to the topological feature. Except that this feature can be defined using a fixed value in the DMD display, the general procedure for forming a moat or “moat feature” is as described in Defining bump features. It can be performed in a similar manner. Furthermore, the moat can extend into or be part of another feature, such as a volume meter. A “moat” can be defined by a substantially non-continuous height reduction of the lens precursor mold and / or a region of the lens precursor mold of substantially zero or zero thickness.

  “Multi-part design” as used herein refers to a design in which essential information for reconstructing a desired profile is contained in two or more files. Further, the two or more files can include one or more separate non-contact and non-continuous surfaces. A multi-part design can include feature separation in (xy) planes, where the depiction of the cross-section of an exemplary lens in a flat space can be a “paper-facing” plane, and a similar flat space An exemplary lens cross-sectional depiction within may also include separation in the (xz) plane, which can be represented by the plane of the paper itself.

  As used herein, an “optical zone” refers to a region of a lens or lens precursor that is visible to the lens wearer after the lens is formed.

  “Optical aberration” as used herein refers to distortion in an image formed by an optical system that may include one or both of low order optical aberrations or high order optical aberrations.

  As used herein, “product” refers to the desired lens or lens precursor. The product may be either “standard product” or “custom product”.

  “Single part design” as used herein refers to a design in which the required information of the desired profile can be represented in one file. A single part design can result in a lens precursor mold that can have either a continuous or non-continuous surface.

  A “stabilization zone” as used herein helps to hold a non-rotationally symmetric contact lens so that it is accurately oriented on the eye, inside the edge feature as well as the power region and Refers to terrain features found outside one or both of the optical zones.

  “Standard product” as used herein refers to a product with limited product parameter effectiveness, such as those where different specific settings are currently provided in separate steps. For example, a standard product can only be used with a sphere magnification parameter of 0.25D steps (eg, -3.00D, 3.25D, -3.50D, etc.) and a cylindrical magnification parameter of 0.50D steps. (Eg, -0.75D, -1.25D, -1.75D, etc.) and cylindrical axis parameters can only be available in 10 ° steps (eg, 10 Product groups can be defined (°, 20 °, 30 °, etc.). Other standard parameters and features provided in a separate process include, but are not limited to, base curve radius, diameter, stabilization profile, and thickness profile.

  “Substrate” as used herein refers to a physical entity on which other entities may be placed or formed.

  “Substructure” as used herein refers to a phase feature or parameter that can support and sometimes affect at least a portion of a flowable lens reactive medium within a lens precursor. The substructure can include one or both of a substrate included in a particular lens design and one or more lens precursor features. Control of the flowable lens reactive medium, for example, limits the amount of lens reactive medium in the lens precursor in one or more segments and affects the resulting optical properties of the free-form ophthalmic lens. Providing.

  As used herein, an “object file”, sometimes referred to as an “object lens design”, is data representing a lens design, thickness map, lens precursor design, lens precursor feature design, or a combination of the above. Point to. Target files can be either hydrated or unhydrated, flat or curved space, 2D or 3D space, including but not limited to geometric drawings, power profiles, shapes, features, thicknesses, etc. It can be represented by a method. The subject file can contain data related to regularly or irregularly spaced grids.

  “Thickness map” as used herein refers to a representation of a two-dimensional or three-dimensional thickness profile of a desired product, or lens precursor. The thickness map may be one or both of a flat space coordinate space and a curved space coordinate space and may contain data associated with regularly or irregularly spaced grids.

  "Volume" as used herein refers to a feature that controls the flow of a reactive mixture of fluid in relation to the outer edge of the lens precursor or another feature or region of the lens precursor. . The volume meter allows one or more of the following desired minimum height, depth, angular width, length, shape, and angle of the minimum energy surface to produce the desired lens precursor shape: can do. The parameters that define the volume meter are often selected based at least in part on parameters that define adjacent lens features and the desired lens shape.

  A “voxel” as used herein, also referred to as a “chemoradiation voxel”, is a volume element that represents a value on a regular or irregular grid in three-dimensional space. A voxel may be considered a three-dimensional pixel, however, a pixel represents 2D image data, while a voxel includes a third dimension. Furthermore, while voxels are often used for visualization and analysis of medical and scientific data, in the present invention, voxels define actinic radiation dose boundaries that reach a specific volume of a reactive mixture, and Is used to control the rate of crosslinking or polymerization consisting of that specific volume of the reactive mixture. As an example, a voxel in the present invention is in a single layer that is conformal to a 2D mold surface where actinic radiation is in the common axial dimension of each voxel and can be directed perpendicular to the 2D surface. Is considered to exist. As an example, the specific volume of the reactive mixture may be crosslinked or polymerized according to 768 x 768 voxels.

  The present invention includes a method and apparatus for forming a lens precursor with phase features as part of the lens precursor mold / lens precursor substructure. The substructure can serve to control at least a portion of the non-polymerizable or partially polymerized flowable reactive media portion of the lens precursor. The lens precursor can be further processed into an ophthalmic lens.

Lens Precursor Features Many types of ophthalmic contact lenses can be ophthalmic lenses that are much more complex than those expected from their appearance and those currently used. In some types of ophthalmic lenses, the underlying features are essential to allow maximum performance, comfort, and different functionality. In the description of the technology according to the present invention in the present specification, a number of such characteristic parts related to the manufacturing technology of an ophthalmic lens by a free shaping method will be described. After describing the novel aspects and some of the nature of these features, then in an exemplary embodiment of the invention, how features can be formed, act and interact with each other And a description depicting the use of an exemplary freeform process that can enable a desired aspect of the desired product or target lens design. This in turn provides a basis for describing some exemplary methodologies consistent with the techniques of the present invention herein.

  Proceeding to FIGS. 1A and 1B, it will be apparent that the depiction of the cross section demonstrates the degree of complexity that a group of features can define. The two figures depict the basic aspect of free-form technology, ie the lens precursor. The lens precursor is above the gel point combined with non-polymerized or partially polymerized regions of the flowable lens reactive medium below the gel point so that the definition of the term provides a complete definition. A combination of polymerized region (s). Non-polymerizable or partially polymerized flowable lens reactive media below the gel point can provide a framework for producing ophthalmic lens products with high optical performance.

  At least a portion of the flowable lens reactive medium flows across the gelled substructure and can flow to a particular state, such as a minimum energy surface state. This can allow for the creation of the desired optically active area and can produce a much smoother surface, but can also add to the complexity of producing an overall lens product. For example, the use of novel freeform design and generation techniques can enable lens products that use aspects of a fluent lens reactive medium in combination with a substructure.

  Referring again to FIGS. 1A and 1B, FIG. 1A depicts a cross section of a gelled substructure of a single exemplary lens precursor in flat space, sometimes referred to as a lens precursor mold. FIG. 1B depicts the same substructure in conjunction with a flowable lens reactive media layer on a gelled substructure and in a flat space.

  In FIG. 1A, the side of the exemplary lens precursor mold 100A is placed in a flat space where the natural three-dimensional curvature of the ophthalmic lens device has been removed so that the thickness of the feature itself can be clearly assumed. A cross-sectional view is depicted. An exemplary cross section includes a group of different lens precursor features. The lens precursor mold 100A can include one continuous lens edge 110A. This feature can be described as continuous so as to define the fact that the lens edge is adjacent or connected to a neighboring feature shown as item 115A in FIG. 1A in cross section. As in some embodiments, being able to exist around the entire periphery depicted in item 110E of FIG. 1E will also help to understand the nature of this lens precursor edge feature.

  Following the features shown in FIG. 1A, at 115A, a continuous stabilization zone feature is depicted. This stabilization zone feature is represented as item 115E on either side of the exemplary lens when viewed in the plan view of FIG. 1E. As noted above, these types of lens precursor features can be important in providing different functions. In particular, the stabilization zone feature can be important in providing the ability to position the ophthalmic lens in the correct position and / or orientation, for example when the ophthalmic lens is over the user's eye. In some stabilization zone features, the features can take a shape with a greater thickness to perform its function, as shown on the left side of FIG. 1A, item 115A. Further, from the observation of an exemplary display that includes the flowable lens reactive medium 135B of FIG. 1B, the flowable lens reactive medium in the region of the feature 115B has a locally thicker nature of the stabilization zone feature 115B. It will be clear that it may have certain effects due to the topological aspect.

  Continuing with the exemplary cross-section of FIG. 1A, an exemplary continuous volumeometer feature is depicted at 120A. As described in detail in subsequent sections, the shape of this feature can have various implications. In this cross-sectional position, this feature 120A on the left side of the cross-section has two lower shelves and a second higher shelf adjacent to the high thickness region of the stabilization zone feature 115A on the left side of the cross-section. It can consist of parts. Alternatively, on the right side of the cross section where the stabilization zone feature 115B may not be as thick, the volume meter feature 120B may be a simple shelf that is approximately the same thickness as the stabilization zone. Due to the nature of some flowable lens-reactive materials, this exemplary difference in volume meter cross-section adjacent to different height features can allow the desired properties to be achieved in the final product. . For example, a volumemeter may need to have more “volume” potential so that the flowable medium flows to the next relatively thick topological feature.

  The optical zone is depicted at 125A. The optical zone or part thereof may be on the eye of the ophthalmic lens user, in front of the part of the eye where light passes through the eye. Further, the combination of optical zone infrastructure 125B and flowable media 135B within the optical zone can produce a combined thickness profile that can result in the desired optical properties of the entire light zone.

  Yet another characteristic property can be the lens edge. The lens edge can be on the outer edge of the lens precursor and can be the same or different height or angular width around the entire circumference of the lens precursor. The lens edge can be continuous around the lens precursor or can be in a separate non-continuous zone. The lens edge can contain a flowable lens-reactive medium during various stages during lens manufacture, preventing it from flowing or controlling its flow beyond the edge of the lens precursor It can act like a fence structure that provides a well-defined edge.

  In FIG. 1A, the height of the lens edge 110A on the lens precursor can be in the range of 0.001 mm to 1.000 mm to provide at least a plurality of desired foundation structures, In some cases, the flowable reactive medium near the edge of the lens precursor can be affected. Defining the local shape or height profile is to increase the intensity, wavelength, or time of chemoradio exposure of the monomer mixture at a specific location to yield a higher area, and vice versa to provide a lower area Can be realized by various methods. These higher areas, for example, have higher lens edges at several separate portions of the defining edge, and control the flowable lens reactive media, resulting in thicker lenses at their multiple portions. It can serve the function of providing a lens that includes an edge.

  The length of the lens edge may also vary with different designs and may include a length in the range of 0.001 mm to 2.00 mm. The lens edge can be continuous around the circumference or can be in a segment segmented by the object design. Thus, the length of the edge feature can form the minimum energy surface of the flowable lens reactive mixture.

  115A depicts the phase characteristics of the continuous stabilization zone. Stabilization zone phase features may therefore be present in the lens precursor and have a height or thickness range of about 0.050 mm to 1.000 mm and a length range of about 0.001 mm to 4.500 mm. be able to. These stabilization zones may have a high variety of design aspects and may be continuous, segmented, or discontinuous. For example, there can be one stabilization ring that includes two proportionally large protruding areas for stabilization functionality.

  At 120A, the volume meter phase feature is depicted. As described, the volume meter feature can support a controlled flow of fluid-reactive mixture between one or more regions of the lens precursor. Thus, when this feature can be defined by a locally less volume of gelled material, the flow of the flowable medium can be considered a “controlled” property. When there is a controlled flow, a larger volume of the flowable lens reactive mixture can be present therein, so that a larger volume of the flowable lens reactive mixture is within these regions of the lens precursor. Can then be cured.

  The volume meter can be continuous around the circumference or it can be discontinuous. The height or thickness of the volume meter can include a plurality of parts having a range of 0.001 mm to 1.000 mm and a range of lengths of 0.001 mm to 4.500 mm.

  Referring back to FIG. 1B, a cross-sectional representation of a lens precursor 100B that includes a single lens precursor feature 105B of multiple types and heights is illustrated. The lens precursor includes a single continuous lens edge 110B, a single stabilization zone feature 115B, a single continuous volumeometer feature 120B, a single continuous optical zone 125B, and a minimum An energy surface 130B and a flowable lens reactive medium 135B can be included. As depicted, features that can act individually or with each other to produce a minimum energy surface for the flowable lens reactive medium to be present in lower and sometimes minimum surface energy states 130B. The minimum energy surface 130B can be generated by a reactive medium that is polymerized at or above the gel point to form a lens precursor having the same. As depicted, the minimum energy surface can be a smooth and continuous surface. However, it is possible to implement the invention so that the minimum energy surface is in a smooth separate segment.

  Thus, the present invention takes advantage of the concept of a minimum energy surface that can derive its shape as a result of the way in which a flowable lens reactive medium can exist and flow over a lens precursor type substructure. Thus, the flow and amount of flowable lens reactive media present on or adhering to a particular portion of the lens precursor mold can affect the shape and topology of the lens precursor mold. For example, a lens precursor feature within a lens precursor mold cannot itself produce a smooth and continuous profile, but the resulting lens precursor is a combination of a lens precursor mold and a flowable lens reactive medium, That is, when viewed as the item 105B, it can be smooth and continuous in practice. This concept is further explained in subsequent sections herein.

  Referring now to FIG. 1C, a cross-sectional representation of another exemplary lens precursor 100C that includes different types of lens precursor features 105C is illustrated. However, a characteristic difference in this lens precursor design is that some of the depicted feature sites can occur once in this design, while other feature sites can occur multiple times. It is.

  In the exemplary lens precursor 100C, the lens precursor includes a single lens edge 110C, multiple stabilization zone features 115C, multiple volumeometer features 120C, and a single optical zone 125C. Including a minimum energy surface 130C and a flowable lens reactive medium 135C. In some cases, such as multiple variations of stabilization zone features, a single cross-sectional depiction is, for example, a volume meter visible to the left of the stabilization zone feature depicted on the left, and its stabilization At least two different variations of the lens precursor feature can be manifested, such as a volumemeter that appears to the right of the zone feature.

  Multiple deformations of features will become more apparent by observing the device plan. In a more general sense, there can be a high variety of embodiments of lens precursor designs that can be the source of multiple occurrences of specific lens precursor features. (The multiplicity of a particular feature is not limited to the stabilization zone and volume meter, as the design can include any one or more of the features described above, depending on the target lens design of the particular product.) .

  Referring now to FIG. 1D, a cross-sectional view of a lens precursor 100D is shown that includes different types of lens precursor features 105D that occur in addition to the moat features 140D in single and multiple cases by design. ing. In this exemplary lens precursor 100D, a single lens edge 110D, multiple stabilization zone features 115D, multiple volumeometer features 120D, a single moat feature 140D, and multiple optics. A zone 125D, a minimum energy surface 130D, and a flowable lens reactive medium 135D are included. It will be apparent to those skilled in the art that very complex ophthalmic lenses can be designed when the individual lens precursor features are combined and organized together to allow for target lens design.

  As depicted in FIG. 1D, moat feature 140D represents another type of lens precursor feature or phase feature that may be included in the design. The moat feature may be significantly lower in height than the surrounding features, and can typically be formed in some manner similar to a volume meter. The moat can extend into or be part of another feature, such as a volume meter. Further, the moat may be composed of sections below the gel point in the lens precursor (and thus can be defined within the portion of the lens precursor that has reached the gel point).

  Referring now to FIG. 1E, a top view representation of an exemplary non-circular lens precursor 105E structure including single and multiple different types of lens precursor features is depicted. Also seen in the top view is another type of lens precursor feature referred to as the drain channel 145E that has not yet been described in the description relating to the previous cross section. The drain channel feature 145E can help reduce the volume of the one or more reduced gelling feature (s). Thus, the nature of the shape of the drain channel can be such that the additional volume of the flowable lens reactive mixture is pulled away from a particular area.

  In this exemplary lens precursor 100E, the list of all lens precursor features that can be seen from a top view point is the exhaust channel feature 145E, a single lens edge 110E, and multiple stability. Zonal zone feature 115E, multiple volumeometer feature 120E, and a single optical zone 125E.

  The drain channel feature (s) 145E reduces actinic radiation exposure at one or more voxel location (s) by reducing the exposure signal provided by the DMD command (s) at these locations. Can be generated. In a similar manner, the drain channel feature (s) can be chemistry at one or more voxel location (s) by increasing the exposure signal provided by the DMD command (s) at these locations. It can also be formed by increasing radiation exposure. In either case, the relative change in actinic radiation exposure can produce a relative depression that can occur with a linear shape similar to that of item 145E. Furthermore, from a more general point of view, the exit channel feature (s) can be a fluid lens reactive medium, a polymerized lens precursor, a lens precursor mold, or another other lens precursor feature (s). The shape can allow one or more of flowing across, at least a portion of), flowing away from, and anchoring thereon. The drain channel topographic features may include, for example, continuous or separate segmented depressions within the plurality of portions of the gel precursor gel.

Various characteristics of lens precursor features Additional aspects of the invention include, for example, one or more of one or more of various heights, depths, angular widths, lengths, shapes, and positions. Or resulting from changes in the form and function of the ophthalmic lens that can result from variations in one or more parameters of the plurality of lens precursor features. In addition, combining the same variation in ophthalmic lens characteristics due to variations in lens precursor feature parameters with the various schemes described herein also creates additional inventive techniques.

  Lens precursor features can be controlled parametrically based on an empirically defined relationship between these features and the desired lens characteristics, and these features can be controlled by other lens precursors. It can be associated mathematically or empirically with a feature site. For example, the design of the volume meter feature can be empirically tied to the stabilization zone feature to generate a smooth and continuous surface relationship between them, so that these features combined Helps determine the selection of an appropriate design to incorporate the site, thereby reaching the designed lens properties or functions.

  More importantly, other uses of lens precursor features can include, for example, affecting flow in some portions of the flowable lens reactive medium. The lens precursor features can be further used for lens precursor manufacturing alignment and calibration purposes.

  Additional features can be defined in the gelled material and can include marks that can be visualized during inspection. These marks are used in subsequent manufacturing processes. For example, a substrate used in a freeform process may need to be accurately centered to produce the desired lens precursor, ophthalmic lens, or lens precursor feature. Marks defined in the material gelled by the imaging system can be inspected and compared to the location (s) to be marked, and then provide alignment of the imaging system and physical substrate .

  The lens precursor feature can also be used to determine the optical magnification of the freeform tool. In a non-limiting and illustrative sense, the mark is subsequently measured and then obtained by defining the mark in the gelled material, for example by using an imaging system and specific object dimensions. Provided mark-to-imaging dimensions and allow determination and control of system magnification. This is necessary to ensure that the optical magnification value is one or more of the height, depth, width, length, shape, and position of the feature can be manufactured as desired. May be important with the free-form manufacturing process.

  Optical magnification, along with marks, can be useful in determining and controlling the precise positioning of the substrate. For example, when the lens precursor feature can be used for determination of one or more of alignment, calibration, and optical magnification, the mark is measured via imaging techniques including wavefront techniques. be able to.

  The marks can be defined by lens precursor features and parameters, and can include fiducial marks, also referred to as orientation marks, that can be manufactured on the lens precursor using freeform fabrication methods. The fiducial mark can be used to determine one or more of on-eye lens position, centering, rotation, and movement. Further, imaging techniques and wavefront techniques can additionally be utilized to help determine one or more of the fiducial mark position, size, and shape. An image depicting the detection of fiducial marks on the on-eye lens is illustrated in FIG.

  The mark feature can be formed, for example, in a non-limiting sense, even letters, such as letters or numbers for information transmission. Another type of mark feature that conveys information can be derived from bar codes or other optically recognizable character features. For example, there can be many applications for forming character-type feature portions in ophthalmic lens precursors, such as generating anti-counterfeit feature portions and product lens certifications.

  Additional functionality of the lens precursor features can include creating an optical zone that provides a topological profile that is optical grade and at the same time provides a correction mode for the user's visual acuity. Is the main purpose of the free-formation process. For example, by controlling the topology of gelled surfaces on a pixel-by-pixel basis and controlling the properties of the flowable media above these gelled surfaces and neighboring lens precursor features. The correction surface can be formed. However, when a flat surface of a gelled material having various shapes including, for example, a circular feature is combined with certain fluid media properties, in some cases, a feature called a lenslet when solidified with actinic radiation It will be apparent to those skilled in the art that it forms an approximately spherical shape of the small fluid medium that forms. When these features occur on the lens precursor in isolated or array form, they can have the effect of modifying the refractive power of the area they cover.

Interaction between two or more lens precursor features As described in the previous section, the flow dynamics of a flowable lens reactive medium includes the shape and topology of the features that surround a particular region It can be a complex function of the fluid medium itself, and a number of other factors. In another related aspect of the invention, the effects of neighboring features can be exploited by adjusting the control parameters of these neighboring lens precursor features. Moreover, because these tuned parameters can affect the fluid dynamics of the flowable lens reactive media, the resulting surface after the solidification of the flowable media can also change the design parameters of this lens precursor feature. Can also be influenced by. As a specific and non-limiting example, the angle that can be generated when the flowable lens reactive medium crosslinks from the optical zone to the stabilization zone feature is determined by the control parameters of the volumeometer feature and / or the optical zone. Control can be achieved by modifying the control parameters.

  If the height of the volume meter is reduced at that position between the neighboring stabilization zone feature and the neighboring optical zone, the flowable lens reactive medium is adjusted between these two features. Variations in the shape that take place over the volume meter can be considered and considered in the design. However, this is just one exemplary type of change in which changes in lens precursor features can affect the flowable media on and around other neighboring features, and may be of particular desired There may be other types of changes that can cause effects.

  Another non-limiting example can be described with reference to an astigmatic optical zone where the thickness at the 0 degree plane is different from the thickness at the 90 degree plane. The optical edge can be, for example, 100 microns thick at the 0 degree plane and 150 microns thick at the 90 degree plane. In the lens precursor mold, as already explained, such an optical zone can be surrounded by a volumetric feature, for example one or more stabilization zones with a height of 400 microns can be outside of it. When the stabilization zone and the highest point on the optical zone (150 microns) are angularly aligned, the flowable lens reactive medium will cross-link from the stabilization zone at a height of 400 microns to the highest point on the optical zone. Form on the meter feature. If the same shape and features are used, but the optical zone is now rotated 90 degrees, and the volumemeter and stabilization zone remain in the same orientation as before, the fluent lens reactive medium is now high. A separate cross-link is formed from the 400 micron stabilization zone to the optical zone edge, which is now 100 microns high. Thus, the angle that can be generated when a flowable lens reactive medium crosslinks from an astigmatic optical zone to a stabilization zone feature is obtained by modifying the control parameters (angle alignment) of the stabilization zone or optical zone. Can be controlled.

  Yet another example would involve changing the position of the drain channel feature relative to other features such that the effect of the volume being ejected is different. For example, if the discharge channel of FIG. 12 extends to the exact center of the optical zone, the effect of the discharge channel shown not extending into the optical zone and thus not discharging from the optical zone to the same extent. In contrast, a flowable lens reactive medium will be ejected from just the top of the lens. For example, if there is a rake feature in the optical zone and there is no discharge channel extending into the optical zone, the rake feature cannot be discharged. Accordingly, changes in the depth, width, size and extent and position of the discharge channel affect the shape in which the flowable lens reactive medium settles within a certain period.

  In different freeform processes, the processing of the lens precursor can include stabilization and solidification of the flowable lens reactive mixture portion on the lens precursor to form a lens. A controlled amount of the flowable lens reactive medium can remain on the surface of the lens precursor mold while separating the substrate and lens precursor mold from a container containing excess reactive mixture. In addition to lens precursor features that can help control the amount of flowable lens reactive media that adheres to the gelled portion, combinations of reactive mixtures, removal rates, and / or environmental factors (e.g., temperature, Control of the oxygen level, etc.) can be varied to control the amount of flowable reactive mixture present in the formed lens precursor. Alternatively, a portion of the reactive mixture may be discharged or, conversely, using one of many methods known to those skilled in the art, the additional flowable reactive mixture is converted into a lens precursor. May be added. Each of these possibilities is an interaction between the different lens precursor features, each of their design aspects, and the hydrodynamic nature of the flowable reactive media on the underlying structure underlying the lens precursor features. Different base conditions can be generated that produce an effect.

  In some free-formation methodologies, when the amount of flowable reactive mixture is the same or close to that of the lens precursor, and if appropriate, after the stabilization process, to obtain the desired lens in an unhydrated state The solidification process can be started. Some surfaces cannot become adjacent lenses until the flowable lens reactive media is eventually solidified, as described above for lens precursor features. For example, if there is a moat in part of the zero thickness lens precursor mold. In the case of a zero-thickness moat, the gelled feature may end up near the periphery of the moat feature. Under some circumstances, when the lens precursor is removed from contact with the container of reactive media, the flowable media can remain in the moat. Additional fluid medium from the area surrounding the moat area can then also flow into the moat area. Nonetheless, there may be no gelled material in this area until the flowable medium solidifies, but after solidification, the moat area continues as a part of the gelled lens product after subsequent processing. Can be included.

Method of Forming a Lens Precursor Having Lens Precursor Features Referring now to FIG. 3 (item 300), exemplary method steps that can be used to implement certain exemplary embodiments of the invention are illustrated. ing. In the foregoing description, a number of types of lens precursor features that can be included in a lens design have been described. These exemplary method steps provide a means to design a lens that can incorporate all or some of these various features.

  At 301, patient data can be collected. Data collection can occur at different times using one or more of many techniques well known in the art. For example, physical data can produce topographical inspections that can produce guidance for product base curves, diameter and thickness options, eg low order optical aberration (s) such as spherical power, cylindrical power, and cylindrical axis. Collect through additional refractive correction tests that can be obtained and / or wavefront tests that can produce the essential requirements of intermediate or higher order optical aberrations, including one or more of spherical aberration, trefoil, coma, and pentafoil Can do. The additional data can include data such as, for example, patient information obtained through questionnaires and / or data obtained from received images.

  At 302, one or more subsets of patient data can be selected to confirm optical aberrations. The confirmed optical aberration can be used to select an appropriate standard product design or custom product design. In general, standard products are provided in a separate process and may require some user adaptation to the differences between the more accurate requirements and the closest standard products available. When a bespoke design is created, the bespoke can be in the process of increasing the standard or otherwise available in selectable values that differ from the definition of the standard One or more possible parameters may be included.

  Therefore, the custom-made parameters can be taken into account and can provide more accurate spherical power, cylindrical power, and cylindrical axis (eg -3.125D / -0.47D x 18 °) than standard products. Depending on the particular product and its intended use, it may include base curves, diameters, stabilization profiles, and thickness profiles. For example, the results of collection of specific patient data in step 301, analysis of the data in step 302 can be performed to determine if the desired product has astigmatism correction and, in some cases, more accurate spherical power, cylindrical power, and axes. A determination can be made that a correction to a custom product with a specification of the required parameters can provide the desired recipe.

  At 303, mechanical parameters including one or more of the desired base curve, diameter, and center thickness can be selected. If it is determined that a free-form lens can be appropriate, at 304, one or more lens precursor features and, based on one or both of optical selection 302 and mechanical parameter input 303, and Definition parameters can be selected.

  Continuing with the example described with reference to step 302, the lens design may require that the lens precursor feature, including the stabilization zone, keep the astigmatism correction properly oriented. Can be determined. Furthermore, it may be desirable for the lens to have a single lens edge around the entire periphery of the lens. Due to the astigmatism correction nature of the optical zone, in an illustrative sense, determining that multiple volume meter features may be required to arrive at the desired optical zone design and / or manufacture. Can do.

  To identify the lens, it can be determined that various types of markings will be placed on the feature design. Finally, in the exemplary sense, it can be determined that the drain channel feature will also improve the design and / or manufacturing aspects of the optical zone.

  At 305, target lens thickness maps and their associated files (which may contain a numerical representation of the data file format thickness map) may be generated or identified from the database. At 305, the definition resulting from the optical zone requirement of step 302, the mechanical definition of 303, and the complement of lens precursor features of step 304 can be consolidated into the model. The model determines the theoretical thickness by design that adequately performs the desired function of the various regions. From the model, a thickness map and associated files can be generated. As can be seen from the previous section, the generated design and file can be derived from one or more desired lens precursor features and the desired flowable lens reactive media surface for the target design. .

  To provide some examples of the types of results that can result from step 305, a cross-sectional representation of the subject lens thickness map is shown in FIG. This depiction shows the lens design in the curved space. At 410, a display of the back curve profile is seen. At 420, a front curve profile is seen. Referring to the associated file for this thickness map, it can be a data file that contains position variables in various coordinate systems, such as Cartesian coordinates, polar coordinates, spherical coordinates, or other known mathematical coordinate formats. . Certain thickness values may be included in the associated file for each coordinate display.

  Referring now to FIG. 5, an example of a related data file in which coordinates are displayed in Cartesian coordinates is presented. The subject file and / or lens design can be generated by combining carefully selected optical and mechanical requirements with other features (eg, a type of stabilization mechanism such as a stabilization zone).

  Referring now to FIGS. 6 and 6A, an example of using multiple software programs to generate and output desired optical and mechanical features and generate a target lens design is illustrated. At 610, a customized optical design model is presented whose display may be related to the target thickness of the design. The design can result from the output from the collection of refraction data, as shown in item 615.

  The stabilization zone at 620, and the smart volume meter floor design at item 630, as indicated by item 625, from an Excel-based schedule design, such as a schedule that includes a set of data points as Cartesian coordinates, for example. Can be configured as output. These three model elements can be combined to produce a custom lens design depicted in item 640. There can be numerous ways to create a lens design from the various elements and methods that model these elements, and should not be limited to the specific examples presented.

  As an alternative, the operation performed in step 305 can result in a wavefront object rather than a thickness object. Such an object design can be useful in some cases because the measurement can directly provide a wavefront output. Similar utility of the target lens thickness map that can be generated in step 305 can exist for the target lens wavefront.

  At 306, a model is created to generate a lens precursor mold that can suitably provide a lens precursor that matches the thickness object or wavefront object formed in step 305. There can be a number of means for generating a lens precursor type design thickness map. In some cases, a dynamic fluid media model can be applied that can model the manner in which the fluid media can flow over a solid gelled substrate material.

  Alternatively, a fully empirical algorithm may require the lens precursor mold thickness to yield the target lens design after the flowable medium has reached a steady state based on the results prior to the lens marking process. An approximation of the pattern can be provided. Those skilled in the art will appreciate that numerous modeling techniques that can include a combination of dynamic modeling algorithms, and empirical models, can also be used to convert the target lens thickness map into a model. It is. As a result, the target lens design, thickness map, and associated file for the desired product can be generated from the lens precursor design, thickness map, and file.

  In a general sense, the target file, or portions thereof, are at least partially a conventional 2D design method, a 3D design method, an empirical method, and a combination of both conventional and empirical methods It can be generated by using one or more of them. Examples of conventional methods include ray tracing methods, mathematical formulas, CAD / CAM / CAE, 2D modeling software, 3D modeling software, computer programming languages, Microsoft Excel, static modeling methods, fluid modeling methods, And one or more of computational fluid dynamics software.

  At 308, a DMD display including a DMD subsequence can be generated that can reference the first generated DMD display from a series of displays generated by the iterations. Referring again to FIG. 6, an exemplary representation of the modeled cumulative intensity dosing that is desired to be performed is represented as item 650, which was described in the previous section. It may have been calculated based on a custom lens design, 640.

  Based on the model used in association with the intensity and time of actinic exposure of the reactive monomer mixture, intensity and time values can be calculated on a per voxel basis. These values can be used to generate a DMD display that can perform control of a light system using DMD to expose a suitable substrate to a calculated actinic radiation exposure on a per voxel basis. it can. In addition, there can be numerous ways to convert the required time and intensity values into a DMD representation or DMD subsequence.

  In a non-limiting sense, the DMD display (s) can use grayscale modulation to deliver variable exposure to the voxels associated with the calculated exposure. An alternative method may include exposing the voxels to the maximum intensity exposure at a specific duty cycle or a percentage of the time on the full DMD display. If each voxel has a calculated percentage of time, the DMD display is determined for a number of frames for the entire DMD display (which may be referred to as a “movie”), and then that percentage is relative to the total number of frames. Similar to a movie in relation to the ratio of the number of frames at a particular voxel location with high intensity.

  If the DMD display is used to control an actinic radiation exposure system that can include a DMD as a light modulating element, a lens precursor can be formed on the substrate at step 309. After this treatment occurs, the lens precursor can exist as a gel-formed material, a lens precursor mold, having a flowable media layer that realizes a minimum energy state on the gelled medium. You can also The lens precursor can then be subsequently exposed to actinic radiation to solidify the lens precursor into a fully gelled form, possibly resulting in an ophthalmic lens. Any such lens precursor or lens may be the result of a process step displayed as number 309.

  In step 310, the thickness of the manufactured lens precursor or completed ophthalmic lens can be measured by various methods. These thickness results can then be compared to the thickness maps created in step 305 and their associated files to determine suitability for the desired product design. As described above, the “thickness map” may be a wavefront target map. In these cases, the measurement 310 can obtain the wavefront data itself. It is within the scope of the present invention to implement other methods of measuring lens or lens precursor thickness or wavefront information.

  In some cases, the measurement results in step 310 can yield a lens precursor or lens that is sufficiently close to the target lens design and acceptable. Under such circumstances, the method shown in FIG. 3 can be completed. The measurement result in step 310 may be unacceptable on the other hand. If the result is far from the desired object, it may be desirable in some cases to return to step 303 to radically change the lens precursor design. Accordingly, at 311, optical parameters, mechanical parameters, lens precursor features, lens precursor features, flowable lens reactive media surface parameters, manufacturing process conditions, thickness map, Combinations of related files, DMD displays, etc. may be added, eliminated, or modified and utilized in an attempt to produce a lens precursor that more closely approximates the desired product design / design object.

  Alternatively, the steps described above at 311 may occur when the measuring step at 310 is deemed to give acceptable results. In these cases, the DMD display can represent an acceptable display for the generation of a lens precursor or lens having the designed characteristics. Such representations and related designs can be a desirable starting point for a modified design, where design characteristics significantly approximate acceptable results. Again, in such cases, in 311 and 312, optical parameters, mechanical parameters, lens precursor feature, lens precursor feature parameters, flowable lens reactive media surface parameters, manufacturing process conditions, thickness Combinations of size maps, associated files, DMD displays, etc. may be added, excluded or modified and utilized.

  All of these methods can allow additional feature changes, particularly for the optical zone, to be added in parallel to the method flow. Proceeding to FIG. 3A (item 320), an additional step 327 is seen. In one example of a more general technique of adding design details in this way, intermediate and higher order aberration corrections are added to the target lens design at step 305 or to the lens precursor type design at step 306. Steps that can be performed. It is clear that these separate additional elements can be used in a stand-alone manner, where the added element 327 defines the nature of the area of interest design or lens precursor design that is exclusively relevant.

  Alternatively, what has been added to the file can be combined with the existing definitions of the target lens design and lens precursor type design that resulted in the standard method flow. The added file located at step 327 can be associated with a thickness map associated with the added content, or can be associated with an added wavefront aspect or map for a particular region, as described.

  An alternative process that may share the similarity of step 327 can be understood by referring to FIG. 3B (item 340). In the same or very similar manner, additional feature design aspects can be added to the process flow as additions that cover thickness or wavefront, and the DMD display details are modified by the DMD subsequence. Can do. As shown in step 343, if an intermediate or higher order aberration correction is added directly to an existing DMD display for lens prescription, it may be a non-limiting example of a DMD file. In some cases, DMD subsequences added using mathematical operations may be combined. For example, perform an arithmetic addition operation to calculate and use the sum of voxel values at a particular position for that particular predefined voxel position, replacing that value on a frame-by-frame basis. The DMD display or movie may be changed. Many other types of operations may be possible, including, for example, subtraction, multiplication, division, Boolean operations, and the like.

  In a similar sense, if the DMD subsequence file in step 343 defines a feature that adds additional feature thickness or wavefront equivalent thickness, the addition performed after the existing DMD display is performed By including the frame of the device DMD file, an additional process can occur. It will be apparent that existing frames can be added to the DMD display at any particular location within the DMD display.

  The terms and descriptions in the preceding description of the method of forming ophthalmic lenses and lens precursors with various features that are possible and described are particularly useful for controlling the details of the manufacturing process, The present invention relates to a technique related to free-form manufacturing of ophthalmic lenses and lens precursors using a digital mirror device. The concept according to the invention herein relates to DMD-based free-form technology, but is also more generally applicable. For example, process number 308, named DMD start display, can be associated with generating a control program for a stereolithography manufacturing tool.

  The lens precursor can be formed by using a stereolithography tool to form a lens precursor mold using this type of manufacturing tool. In the second step, for example, a fluid reactive medium can be added onto the lens precursor mold produced by stereolithography. Once the flowable medium is added, the combination can in turn define the equivalent of the lens precursor. The nature of the flow of the flowable medium over the mold may be similar to the flow in the lens precursor free-form per voxel. Thus, an additional methodology is to form a base lens precursor mold that then interacts with the flowable medium and defines lens precursor features by different types of methods that are within the scope of the present invention. Can be derived. In a more general sense, any method, including free-form voxel-based lithography, stereolithography, mechanical lathe processing, and partial molding methods, with just a few examples, constitutes a technique within the scope of this disclosure. can do.

Automating the design and manufacture of lens precursors with features Referring to FIG. 7, a schematic diagram of an exemplary processor that can be used to model software used in some parts of the present invention is depicted. Yes. The controller 700 includes a processor 710 that can include one or more processor components coupled to the communication device 720. The communication device 720 can be configured to communicate information over a communication channel to electronically transmit and receive digital data associated with the functions described herein.

  The communication device 720 can also be used to communicate with one or more human-readable display devices such as, for example, an LCD panel, LED display, or other display device or printer.

  The processor 710 may also be in communication with the storage device 730. The storage device 730 may be a semiconductor storage such as a magnetic storage device (eg, magnetic tape, radio frequency tag, and hard disk drive), optical storage device, and / or random access memory (RAM) device, read only memory (ROM) device, etc. Any suitable information storage device can be provided, including a combination of devices.

  The storage device 730 can store a modeling program 740 for controlling the processor 710. The processor 710 executes the instructions of the program 740 and thereby operates in accordance with the present invention. For example, the processor 710 receives information describing the target lens design, lens precursor, DMD file, patient information, lens optical performance, ophthalmologist office data, lens precursor features, measured thickness profile, etc. be able to. Storage device 730 can also store and transmit all or part of the information sent to the processor in one or more databases 750 and 760.

  Modeling program 740 operates in conjunction with processor 710 to cause apparatus 700 to receive digital data describing one or more optical aberrations associated with the wearer of the ophthalmic lens (FIG. 3, step 302), and the eye Receiving digital data describing at least one desired mechanical parameter of the working lens (FIG. 3, step 303) and receiving input from an operator describing at least one phase feature of the lens precursor type substructure (FIG. 3, step 304), and a DMD display for use in a stereolithographic ophthalmic lens precursor type manufacturing tool is generated (step 308). It also causes the apparatus to receive digital data including a lens precursor mold or a design thickness map of at least a portion of the lens precursor (FIG. 3, step 305 or 306) and the lens precursor produced by the production tool. Receiving digital data including the measured thickness of at least a portion of the mold or lens precursor and comparing the measured thickness to a design thickness map to determine suitability with the desired design (FIG. 3, step 310) and, if desired, an alternative instruction set can be generated for use in the production tool of the ophthalmic lens precursor mold (FIG. 3, step 311).

  In the same manner, the modeling program 740 sends to the device 700 step 312 in FIG. 3, steps 302-308, 3103-112, and 327 in FIG. 3A, and steps 302-308, 3103-112, and 343 in FIG. To operate with the processor 710.

Empirical method of target file determination An empirical determination of a target file or parts thereof can be used to replace and use measured thickness profiles therefrom, or parts thereof, in subsequent target files. The method may include using a freeform fabrication method for manufacturing one or more of the lens, lens precursor, lens precursor mold, and lens precursor feature. For example, a desired optical zone having a stabilization zone feature that is reduced in height compared to the stabilization zone feature designed by the system due to the complex nature of the flowable medium and the gelled type of interaction Sometimes it is only possible to produce Therefore, the stabilization zone feature subsequently calculated by the system was replaced with an improved empirically defined stabilization zone feature with a profile resulting in the corresponding measured thickness, and improved. Manufacturing results can be brought about.

Scheme for Representing Designs in Cross Section Display Referring now to FIG. 8A, a cross section representation of an exemplary non-circular lens precursor 800A in a two-dimensional curved space is depicted. An exemplary lens can be classified as a single part design. By representing the view from above (item 801A) with various cross-sectional representations, the complexity of the actual topological and thickness changes will be shown to some extent. Referring to the focal point of the lens, which in some examples can be the center of the optical zone, the length of the lens material from the focal point to the “right” side edge and the “left” side edge in the cross-sectional view. Because of the similarities, the cross-section 805A illustrates an example of a significantly symmetric (ie, substantially symmetric) thickness profile. Cross sections 810A and 815A illustrate examples of asymmetric thickness profiles because there are different lengths and thicknesses around the focal point with respect to these directions of the cross section.

  Different ways of representing the lens in cross-section can be understood with reference to FIG. 8B, which is a cross-sectional representation of a non-circular exemplary lens precursor 800B in a two-dimensional flat space. (The representation from directly above is depicted as item 801B.) In this exemplary representation where the illustrated thickness profile is emphasized, the flat space representation transforms the shape of the back curve to a flat shape. doing. In this type of representation, cross-sectional view 820B illustrates an example of a significantly symmetric thickness profile. Cross-sectional views 825B and 830B illustrate examples of asymmetric thickness profiles.

Single and multiple part design-background The target file is a feature of continuous surfaces that, when combined, can generate one or more of complete continuous surfaces, non-continuous surfaces, and separate zones. Can be represented by one or more of a feature portion of a non-continuous surface and a separate feature portion. For example, an object file represented by one or both of a single smooth continuous surface and a single non-continuous surface may be common with a single part design, as the shapes in FIGS. 3A and 3B may represent. It can be called. Further, for example, the target file may be represented by multiple distinct features. These types of design representations can be generally referred to as multi-part designs.

Method for Generating Lens Precursors with Features Using Multi-Part Lens Profiles As just described, target lens designs can have distinct properties that make them candidates called multi-part designs. The distinct characteristics can occur randomly as a result of the design process, however, the design can be formed by a direct combination of different design “parts” that are relevant only to specific areas of the complete lens design. More typically, they are formed. When these parts are combined together, a multiple part design can be generated and may be considered as independent "parts".

  Such a multi-part design concept can allow a non-perfect surface or object file of the desired product to be used in the production of the lens precursor. As a result, in practice a complete surface can never be generated, cannot be stored as a single or multiple files, and cannot be transmitted to the manufacturing facility.

  For example, separate, non-smooth, non-continuous data associated only with the optical zone, base curve, and diameter of the desired product can be used by an ophthalmologist to produce the desired product using a contouring process technique. May need to be sent from the office to the manufacturing facility. The transmitted data can itself display or identify only one part of the lens design and can later be combined with other parts for the rest of the complete design. For example, after receiving an optical zone design transmission of a product having a base curve and an overall lens design diameter, these components may be combined with lens edges and desired stabilization zone features.

  In addition, these additional features can be recreated from catalog items at different locations, such as, for example, in a manufacturing facility, in combination with a flowable lens reactive media design, a smooth and continuous manufactured lens precursor. Can be completed. Other lens manufacturing techniques may require that the entire complete surface of the desired product is known. For example, in direct lathe machining of a lens, a diamond tool must follow the complete tool path previously created to cut the entire surface of the desired product.

  Referring now to FIG. 9A, a non-circular single part design and cross-sectional representation of an exemplary lens precursor 900A are shown in both curved and flat spaces. In this display, the entire convex surface may be virtually smooth and continuous. The convex profiles in the cross-sectional views of 905A, 910A, 915A, 920A, 925A, and 930A are also shown as smooth and continuous sections.

  Designation as a “single part design” can be governed by the fact that the method of generating a lens design generates a design aspect from a complete initial feature specification set. Thus, although the resulting lens shape may appear to have separate parts alone, such lenses can still be classified as a single part design because they were combined together in the initial specification.

  Referring now to FIG. 9B, a non-circular single part design and cross-sectional representation of an exemplary lens precursor 900B in both curved and flat spaces is illustrated. It will be appreciated that these depictions show a design in a cross section where the surface is not substantially smooth or continuous. Nevertheless, as suggested, this may be considered a single part design, and features may be selected that provide the non-continuous nature of the design during the initial design process. For example, as shown, the gap in the cross section may be due to a moat feature 990B. Shown at 935B, 940B, 945B, 950B, 955B, and 960B are cross-sectional views of the surface that can clearly show the lack of smoothness and continuity in this single part design.

  Referring now to FIG. 9C, a display of a multi-part design concept for an exemplary lens precursor 900C that is smooth and continuous is presented. Included in this figure is a cross-sectional view of distinct features that can constitute a lens precursor design. For example, three different features represented by 965C, 970C, and 975C. A smooth and continuous convex cross-sectional view 980C generated from this combination of distinct features will also be observed. Also shown is a plan view, item 901C, depicting a smooth and continuous circular multi-part design lens precursor 900C, all in a two-dimensional curved space. Illustrative different “parts” are shown that can be included in this multi-part design and can be an annular lens edge 965C, a stabilization zone feature 970C, and an optical zone 975C. Also shown are a combination of distinct features that produce a smooth continuous convex cross-section 980C, and a plan view of the lens precursor design 900C.

  Referring now to FIG. 9D, a representation of a multi-part design concept for a non-smooth, non-continuous exemplary lens precursor 900D is depicted. Also included in FIG. 9D is a cross-sectional view of separate features that can constitute a lens precursor design. As can be appreciated, the multi-part design may include a non-smooth, non-continuous convex cross-sectional view 985D generated from a combination of distinct features. This plan view can also show a display from directly above this non-smooth, non-continuous circular multi-part design lens precursor 900D. Similarly, these displays may be made in a two-dimensional curved space diagram. Further, as shown, the combination of the annular lens edge 965D feature, the optical zone 975D feature, and the separate feature may be a discontinuous and non-smooth cross-sectional view 985D. There can be discontinuities between the lens edge 965D and the optical zone 975D.

Digital Core Break Concept Referring again to FIGS. 1A, 1B, 1C, 1D, and 1E, many types of lens precursor features may be combined to form different designs. The related object file can be constructed by combining a number of such different feature parts together. Each of these combined features can be selected from one or both of catalog items and non-catalog items. Non-catalog items in this case can indicate what has been newly modeled or created for a particular lens design.

  If the lens design can be formed by a combination of various lens precursor features, a new lens precursor target design can be defined. However, it is clear that many different lenses similar to the target design of the lens precursor can be formed by assembling the same combination of precursor elements, but the values of the parameters may be different.

  For example, the height of a particular stabilization design and / or lens design, the depth of a particular volume meter feature may be different to produce a similar but different design. For some groups of related designs, it may be desirable to keep the limited lens precursor features and / or limited feature control parameters constant within the lens design. When a subset of feature control parameters for a limited group of lens precursor features is kept constant, the parameters of the other features may be different, but the resulting group of designs is called a digital core break. There is a case. Furthermore, one or more digital core break (s) can be present within the lens design. It will be apparent to those skilled in the art from the teachings of this disclosure that the portions of the DMD file or DMD display associated with manufacturing different lenses within a digital core break may be similar or identical to each other.

  To better understand this concept of digital core breaks, consider the theoretical Acuvue Toric Precision Limited ™, a custom-made product generated by the system. There are a number of lenses in this product group that have different values for low order spherical power, cylindrical power, and cylindrical axis correction that can be provided. However, the variation may target only the range of spherical power of −3.00D to 0.00D and the range of cylindrical power of −2.00D to 0.00D. Continuing with this example, regardless of the spherical power, cylinder power, and cylinder axis provided, these products within these various ranges will have the same lens edge, stabilization zone feature, and volume. Can have meter features. Acquire Toric Precision Limited ™ can therefore be considered as having only one digital core break.

  A further example can be that of Acuvue Toric Precision Plus ™, whereby the infinite parameters of low-order spherical power, cylindrical power, and cylindrical axis correction only are -20.00D to + 20.00D. It is a theoretical custom product that can be provided within a wide spherical power range and a cylindrical power range of -10.00D to 0.00D. For example, within each spherical power range of −20.00D to −10.00D, −9.99D to + 9.99D, and + 10.00D to + 20.00D, the lens edge, the stabilization zone feature, and The Volumetric feature can be the same, but can be different in each of the three digital core breaks, so the Accuve Toric Precision Plus ™ can have three digital core breaks.

  An advanced subject file can be generated by starting with a base subject file and modifying it to add properties. For example, a lens design to provide trefoil and coma correction in conjunction with correction for -5.67D spherical power and -4.56D cylindrical power at a 78 [deg.] Cylinder axis is -5.67D /-. 4.56D x 78 ° design by generating the Accuve Toric Precision Plus ™ catalog items and incorporating the desired higher order correction components into these limitedly reproduced catalog items it can.

  In general, there can be numerous schemes and techniques within the scope of the technique of the present invention to generate a DMD file or DMD display. As depicted in FIG. 3, conventional methods can be used.

  In addition, a DMD file or DMD display can also be generated by playing back catalog items that can then be modified as needed. The previous DMD file or DMD display can also be modified in a number of ways, including adding in the DMD file for new or modified features. Similar to the target file, a DMD file and / or DMD display can be generated from the base, target file, DMD file and / or DMD display and can produce intermediate or higher order corrections in the manufactured lens. It can be generated by incorporating instructions into them. An example of a sample portion of a DMD file is shown in both FIGS.

  In some further embodiments, the lens precursor or lens precursor mold can be manufactured through the use of one or both of a DMD file and a DMD display. For example, the relevant data for producing the desired lens precursor 105B or lens precursor mold 100A can be a single DMD file, such as, for example, a lens edge, a stabilization zone feature, and instructions for generating an optical zone, or It can be accommodated in a DMD display. Further, for example, relevant data for producing a desired lens precursor or lens precursor mold may be contained in multiple DMD files or DMD displays, for example, one DMD file or DMD display may be a lens edge. And may include instructions for generating stabilization zone features, while different DMD files or DMD displays may contain instructions for generating optical zones and discharge channel features. Further, the relevant data for producing the desired lens precursor features within the desired lens precursor or lens precursor mold may be distributed across, for example, one or both of a DMD file and a DMD display. FIG. 11 shows an example of a sample DMD display that is rotated 180 ° about the y axis and rotated 45 ° counterclockwise in the xy plane.

  The entire DMD file or DMD display, or portions thereof, can be used to overwrite the preceding DMD file or DMD view, or portions thereof. For example, a DMD file that includes a circumferential discharge channel feature can be created on the previous DMD file to allow the discharge channel feature to be manufactured in the lens precursor without changing the previous DMD file. You may superimpose. An example of a DMD file that includes a circumferential discharge channel in addition to a sample DMD display is shown in FIG. Another example is to change the DMD file to the previous DMD display to change one or both of the edge shape and profile of the manufactured lens precursor, as illustrated in FIGS. 13A and 13B. It may be used by overlapping.

  FIG. 13A shows a 180 ° rotation around the y axis and 45 ° counterclockwise in the xy plane compared to a lens made from the DMD display whose photo is shown in FIG. 13B. FIG. 6 illustrates an example of a sample DMD display having a DMD file containing circumferential discharge channel commands with a DMD file containing modified edge curvature command sections to be made.

  Complete or incomplete design target file, DMD file, DMD display, DMD repeat display, catalog item, non-catalog item, etc., other complete or incomplete design target file, DMD file, DMD display, DMD repeat display, catalog It can be combined with items, non-catalog items, etc., and can be incorporated into DMD files and DMD displays, from which desired lens precursors can be manufactured. For example, if only a description of the thickness of the optical zone is communicated to the manufacturing facility, it can be converted to a DMD file and combined with another DMD file that can contain lens edges and stabilization zone features. Can do. Thus, the lens precursor may be manufactured without any particular complete lens design or lens precursor design profile. For example, if a DMD file that is not individual or combined describes a complete surface profile, the flowable lens reactive media will still connect the optical zone to the stabilization zone feature, thereby completing the surface profile. Can be made.

  The compatibility of the lens precursor or lens precursor mold with the design object file can be measured before, after, or before and after the solidification process. The resulting measurement results can be used in an iterative loop, allowing the production of the desired lens precursor 105. An example of the lens design, DMD display, and display of two cross sections (at 45 ° and 135 °) of the measured lens precursor in flat space is illustrated in FIG.

  In some cases, the manufactured lens precursor cannot accurately match the target file or fall within certain acceptable criteria. For example, the manufactured lens precursor may include regions that can be one or more of the states that are thicker than desired, thinner than desired, and desired target thickness. There may be several options for producing a subsequent lens precursor that can be closer to the target file than its predecessor. For example, the options include the same DMD display with the same manufacturing process conditions as in the previous attempt, the modified DMD display with the same manufacturing process conditions as in the previous attempt, the same DMD display and the modified One or more of the following manufacturing process conditions and modified DMD display and modified manufacturing process conditions may be used.

  One or both of the DMD file and the DMD display may be modified in many different ways, and one or more of the differences between experience and the measured lens precursor and the desired thickness map or It may be based on both. For example, changing limited lens precursor feature design values and parameters in files such as optical zones, adding values and parameters to produce additional lens precursor features such as moat features Removing the values and parameters of the limitedly manufactured lens precursor features, such as the discharge channel features, and the values of the limitedly manufactured lens precursor features, such as the volumeometer features, and The DMD file may be modified by one or more of spatially redistributing parameters.

  Describes the generation of lens precursor features, lenses having various different features and methods of generating lens precursors, and the characteristics and methods of forming DMD displays and DMD files for forming lenses and lens precursors In order to do that, a specific example has been described. These examples are illustrative only and are not intended to limit the scope of the invention in any way. Accordingly, this description and the claims are intended to cover all modifications and alternatives that may be apparent to those skilled in the art.

Embodiment
(1) A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A lens edge feature located along or adjacent to at least a portion of the lens edge,
A lens precursor mold, wherein the lens edge feature comprises a fence structure configured to receive a flowable lens reactive medium present within an outer periphery of the lens precursor mold.
(2) The lens precursor mold of embodiment 1, wherein with increasing distance from the lens edge, the thickness of the fence structure decreases from the maximum thickness, thereby forming an inwardly facing fence surface. .
(3) The lens precursor mold according to embodiment 2, wherein the maximum thickness portion of the fence structure is separated from the lens edge portion.
(4) The lens precursor mold according to embodiment 3, wherein the decrease in thickness is continuous.
(5) The lens precursor mold according to embodiment 4, wherein the fence surface facing inward is concave on the surface that accommodates the axis of the lens.

(6) The lens precursor according to embodiment 5, wherein the lens edge feature is continuous around the lens precursor mold.
7. The lens precursor of embodiment 6, wherein the lens edge feature is present in a separate non-contiguous zone.
(8) The lens precursor according to embodiment 7, wherein the height of the lens edge characteristic portion is 0.001 mm to 1 mm.
(9) The lens edge feature is higher in several separate parts of the lens edge and controls the flowable lens reactive medium to provide a lens with thicker edges in these parts. The lens precursor according to Embodiment 8.
(10) The lens precursor according to embodiment 9, wherein a radius range of the lens edge characteristic portion is 0.001 mm to 2 mm.

(11) A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A moat feature present in the outer periphery of the lens precursor mold,
A lens precursor mold, wherein the moat feature is defined by a substantially non-continuous decrease in the height of the lens precursor mold.
12. The lens precursor mold according to embodiment 11, wherein the moat feature is defined by a region of the lens precursor mold having a thickness of 0 to 0.2 mm.
13. The lens precursor mold according to embodiment 11, wherein the moat feature is defined by a region of the lens precursor mold having substantially zero or zero thickness.
(14) a lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A moat feature portion present in the outer periphery of the lens precursor mold, and
A lens precursor mold, wherein the moat feature is defined by a region of the lens precursor mold of substantially zero or zero thickness.
(15) a lens precursor type,
A lens edge, wherein the lens edge defines an outer periphery of the lens precursor mold; and
A plurality of drain channel features, each drain channel feature including an elongated depression and arranged in parallel and configured to allow flow of a flowable lens reactive medium across the lens precursor mold. A lens precursor mold comprising: a plurality of discharge channel features.

(16) The lens precursor mold according to embodiment 15, wherein each discharge channel feature is a continuous depression.
The lens precursor mold according to embodiment 15, wherein each discharge channel feature comprises a separate segmented depression.
18. The lens precursor mold according to embodiment 17, wherein the discharge channel feature extends radially from a particular area of the lens precursor mold and pulls the flowable lens reactive medium away from the area.
19. The lens precursor mold according to embodiment 18, wherein the discharge channel feature extends radially in substantially all directions.
20. The lens precursor mold of embodiment 18, wherein the discharge channel features extend radially in a limited number of directions, thereby forming a fan-shaped discharge area.

(21) The lens precursor mold according to embodiment 20, wherein the fan-shaped discharge area has a depression angle of 2 to 360 degrees, such as 30 to 120 degrees or 60 to 90 degrees.
(22) The drainage channel features provide circumferential drainage channels at or toward their outer ends, toward or toward their inner ends, or at other locations, or any combination of locations. The lens precursor mold according to embodiment 21, further comprising:
(23) a lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A lens edge feature located along at least a portion of the lens edge, an optical zone located within the outer periphery of the lens precursor mold, and a stabilization zone feature located within the outer circumference of the lens precursor mold. A plurality of lens features selected from the group consisting of:
The flowable reactive mixture is present in the outer periphery of the lens precursor mold between at least two of the plurality of lens features, and / or the flowable reactive mixture after a period of time. A lens precursor mold comprising a volumeator feature configured to control the shape to which the lens settles.
(24) The volume meter feature controls the desired height, depth, angular width, length, shape, and / or angle of the minimum energy surface of the flowable reactive mixture to provide a desired lens precursor. Embodiment 24. A lens precursor mold according to embodiment 23, configured to generate a body shape.
(25) The volume meter feature comprises a section composed of two parts: a lower shelf and a higher shelf adjacent to a relatively higher thickness region of the stabilization zone feature. A lens precursor mold according to embodiment 24.

26. The lens precursor mold of embodiment 25, wherein the volume meter feature comprises a section that is a shelf that is substantially the same height as an adjacent stabilization zone feature.
27. The lens precursor mold according to embodiment 26, wherein the volume meter feature is continuous around the circumference of at least one of the plurality of lens feature.
(28) The lens precursor mold according to embodiment 26, wherein the volume meter feature is discontinuous.
(29) The volume meter feature is adjacent to the stabilization zone feature and is circumferentially between 30 and 120 degrees, for example between 45 and 90 degrees, or between 50 and 70 degrees around the lens axis. 29. A lens precursor mold according to embodiment 28, which extends.
(30) The lens precursor mold according to embodiment 29, wherein a part of the volume meter characteristic part has a height of 0.001 mm to 1 mm.

(31) The lens precursor mold according to embodiment 30, wherein a part of the volume meter characteristic part has a radius range of 0.001 mm to 4.5 mm.
32. A lens precursor mold according to embodiment 31, wherein the volume meter feature is a moat feature having a radius range of 0.001 mm to 1 mm, for example, about 0.5 mm.
(33) A method of designing a lens precursor mold,
Defining a lens precursor type design, the design comprising:
A lens edge defining an outer periphery of the lens precursor mold;
A plurality of lens feature portions, a lens edge feature portion existing along at least a part of the lens edge portion, an optical zone existing in the outer periphery of the lens precursor mold, and in the outer periphery of the lens precursor mold A plurality of lenses selected from the group consisting of a stabilization zone feature that is present in the volume and a volumeometer feature that is present within the outer periphery of the lens precursor mold between at least two of the plurality of lens feature portions Including a characteristic part,
Each of the lens feature is defined parametrically, and the parameter defining at least one lens feature is at least one of the parameters defining one or more adjacent lens feature and a desired lens shape. A method selected based in part.
34. The method of embodiment 33, wherein the at least one lens feature is a volumeometer feature.
(35) The desired angle generated when the flowable lens reactive medium crosslinks from the optical zone to the stabilization zone feature defines the volume meter feature between the optical zone and the stabilization zone feature. 35. The method of embodiment 34, wherein the method is controlled by selecting the parameter and optionally the parameter of the optical zone.

(36) A method for producing a lens precursor mold,
Designing a lens precursor mold according to any of embodiments 33-35;
Manufacturing a lens precursor mold to the design.
(37) An ophthalmic lens precursor,
A lens precursor mold according to any of embodiments 1-32,
A crosslinkable medium comprising a light absorbing component;
A lens precursor mold comprising: a first surface that includes a portion of a first crosslink density that is at least partially polymerized at or above the gel point and includes the feature.
A second crosslink density degree of cure less, wherein the second fluid surface, at least a portion of the second surface can be incorporated into an ophthalmic lens. an ophthalmic lens precursor comprising: a second fluid surface comprising a than the gel point).
38. A method of manufacturing an ophthalmic lens comprising processing the lens precursor of embodiment 37 so as to stabilize at least a portion of the second fluid surface.
(39) The processing solidifies at least a portion of the second fluid surface using actinic radiation to a crosslinking density that is at least partially polymerized at or above the gel point. 40. The method of embodiment 38, further comprising:
(40) An apparatus for performing a method of generating an instruction set for use in an ophthalmic lens precursor mold manufacturing tool comprising:
A processor;
A storage device for digital data;
Executable software stored on the digital data storage device and executable on demand, operating in conjunction with the processor,
Receiving digital data describing one or more optical aberrations associated with a wearer of the ophthalmic lens;
Receiving digital data describing at least one desired mechanical parameter of the ophthalmic lens;
Executable software for receiving input from an operator describing at least one phase feature of the lens precursor type substructure and generating the instruction set for use in the ophthalmic lens precursor type manufacturing tool A device comprising:

(41) A time-based instruction that the ophthalmic lens precursor type manufacturing tool comprises a stereolithography manufacturing tool including a digital mirror device, and wherein the instruction set can be used to control activation of the digital mirror device. 41. The apparatus of embodiment 40, which is a DMD display that includes data points.
(42) the executable software operates in conjunction with the processor to the device;
Receiving digital data including a design thickness map of at least a portion of the lens precursor mold or lens precursor;
Receiving digital data including a measured thickness of at least a portion of a lens precursor mold or lens precursor produced by the production tool;
The measured thickness is compared with the design thickness map to determine compatibility with the desired design and, if necessary, an alternative for use in the ophthalmic lens precursor mold manufacturing tool 42. The apparatus of embodiment 41, wherein the apparatus generates an instruction set.
43. The apparatus of embodiment 42, wherein the mechanical parameters include one or more of a base curve, a diameter, and a center thickness.
44. The apparatus of embodiment 43, wherein the optical aberration may include one or more of low order aberrations, mid order aberrations, and high order aberrations.
(45) wherein at least one feature is a portion of the lens precursor mold that can be mathematically described by one or more of the height, length, width, shape, and position of the feature 45. The apparatus of embodiment 44, comprising.

46. The apparatus according to embodiment 43, wherein the at least one feature includes the lens edge feature according to any of embodiments 1-10.
47. The apparatus according to embodiment 46, wherein the at least one feature includes a moat feature according to any of embodiments 11-14.
48. The apparatus according to embodiment 47, wherein the at least one feature includes an exhaust channel feature according to any of embodiments 15-22.
49. The apparatus according to embodiment 48, wherein the at least one feature comprises a volumeometer feature according to any of embodiments 23-32.
(50) A plurality of feature parts are defined parameterically, and the parameter defining at least one lens feature part is at least one of the parameters defining one or more adjacent lens feature parts and a desired lens shape 50. The apparatus of embodiment 49, selected in part.

51. An apparatus according to embodiment 49, wherein at least one feature comprises a stabilization zone feature or optical zone portion of the lens precursor type.

Claims (43)

A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A lens edge feature located along or adjacent to at least a portion of the lens edge,
The lens edge feature comprises a fence structure configured to contain a flowable lens reactive medium present within an outer periphery of the lens precursor mold;
As the distance from the lens edge increases, the thickness of the fence structure decreases from the maximum thickness, thereby forming a fence surface facing inward,
A lens precursor mold wherein the maximum thickness portion of the fence structure is spaced from the lens edge.   The lens precursor mold of claim 1, wherein the thickness reduction is continuous.   The lens precursor mold according to claim 2, wherein the inwardly facing fence surface is concave in a plane that accommodates the axis of the lens. The lens edge feature portion is continuous around the lens precursor form, the Lens Precursor die according to claim 3. The lens edge features sites are present in separate discontinuous zones, Lens Precursor die according to claim 4. The lens edge height of the characteristic portions is a 0.001Mm～1mm, Lens Precursor die according to claim 5. The lens edge feature is higher in several separate portions of the lens edge and controls a flowable lens reactive medium to provide a lens with thicker edges in those portions. lens precursor type described 6. The lens edge radial extent of the characteristic portions are 0.001Mm～2mm, Lens Precursor die according to claim 7. A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A moat feature portion present in the outer periphery of the lens precursor mold, and
A lens precursor mold, wherein the moat feature is defined by a substantially non-continuous decrease in the height of the lens precursor mold.   The lens precursor mold according to claim 9, wherein the moat feature is defined by a region of the lens precursor mold having a thickness of 0-0.2 mm.   The lens precursor mold according to claim 9, wherein the moat feature is defined by a region of the lens precursor mold having substantially zero or zero thickness. A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A moat feature portion present in the outer periphery of the lens precursor mold, and
A lens precursor mold, wherein the moat feature is defined by a region of the lens precursor mold of substantially zero or zero thickness. A lens precursor type,
A lens edge, wherein the lens edge defines an outer periphery of the lens precursor mold; and
A plurality of drain channel features, each drain channel feature including an elongated depression and arranged in parallel and configured to allow flow of a flowable lens reactive medium across the lens precursor mold. A plurality of drainage channel features,
Each drain channel feature has a separate segmented depression,
The discharge channel features radiate out from a specific region of the lens precursor mold, pulling the flowable lens reactive medium away from the region;
A lens precursor mold in which the discharge channel features extend radially in substantially all directions.   The lens precursor mold of claim 13, wherein the discharge channel features extend radially in a limited number of directions, thereby forming a fan-shaped discharge area.   The lens precursor mold according to claim 14, wherein the fan-shaped discharge area has a depression angle of 2 to 360 degrees.   The discharge channel features further comprise circumferential discharge channels at or toward their outer ends, toward or toward their inner ends, or at other locations, or any combination of locations. The lens precursor mold according to claim 15. A lens precursor type,
A lens edge defining an outer periphery of the lens precursor mold;
A lens edge feature located along at least a portion of the lens edge, an optical zone located within the outer periphery of the lens precursor mold, and a stabilization zone feature located within the outer circumference of the lens precursor mold. A plurality of lens features selected from the group consisting of:
The flowable reactive mixture is present in the outer periphery of the lens precursor mold between at least two of the plurality of lens features, and / or the flowable reactive mixture after a period of time. A lens precursor mold comprising: a volume meter feature configured to control a shape to which the lens is fixed.   The volume meter feature controls the desired height, depth, angular width, length, shape, and / or angle of the minimum energy surface of the flowable reactive mixture to form a desired lens precursor shape. The lens precursor mold of claim 17, wherein the lens precursor mold is configured to produce   The volume meter feature comprises a section composed of two parts: a lower shelf and a higher shelf adjacent to a relatively higher thickness region of the stabilization zone feature. The lens precursor mold according to 18.   The lens precursor mold of claim 19, wherein the volume meter feature comprises a section that is a shelf that is substantially the same height as an adjacent stabilization zone feature.   21. The lens precursor mold of claim 20, wherein the volume meter feature is continuous around an outer periphery of at least one of the plurality of lens feature portions.   21. The lens precursor mold of claim 20, wherein the volume meter feature is discontinuous.   23. The lens precursor mold of claim 22, wherein the volume meter feature is adjacent to a stabilization zone feature and extends circumferentially between 30 and 120 degrees about the lens axis.   24. The lens precursor mold according to claim 23, wherein a part of the volume meter feature has a height of 0.001 mm to 1 mm.   25. A lens precursor mold according to claim 24, wherein a portion of the volume meter feature has a radius range of 0.001 mm to 4.5 mm.   26. A lens precursor mold according to claim 25, wherein the volume meter feature is a moat feature having a radius range of 0.001 mm to 1 mm. A method for designing a lens precursor mold, comprising:
Defining a lens precursor type design, the design comprising:
A lens edge defining an outer periphery of the lens precursor mold;
A plurality of lens feature portions, a lens edge feature portion existing along at least a part of the lens edge portion, an optical zone existing in the outer periphery of the lens precursor mold, and in the outer periphery of the lens precursor mold A plurality of lenses selected from the group consisting of a stabilization zone feature that is present in the volume and a volumeometer feature that is present within the outer periphery of the lens precursor mold between at least two of the plurality of lens feature portions Including a characteristic part,
Each of the lens feature is defined parametrically, and the parameter defining at least one lens feature is at least one of the parameters defining one or more adjacent lens feature and a desired lens shape. A method selected based in part.   28. The method of claim 27, wherein the at least one lens feature is a volumeometer feature.   The parameter wherein the desired angle generated when the flowable lens reactive medium crosslinks from the optical zone to the stabilization zone feature defines the volumeometer feature between the optical zone and the stabilization zone feature 29. and optionally controlled by selecting the parameter of the optical zone. A method for producing a lens precursor mold, comprising:
Designing the lens precursor mold according to any one of claims 27 to 29;
Manufacturing a lens precursor mold to the design. An ophthalmic lens precursor,
The lens precursor mold according to any one of claims 1 to 26,
A crosslinkable medium comprising a light absorbing component;
A lens precursor mold comprising: a first surface that includes a portion of a first crosslink density that is at least partially polymerized at or above the gel point and includes the feature.
A second fluid surface comprising a second crosslink density of curing below the gel point, wherein at least a portion of the second surface can be incorporated into an ophthalmic lens. And an ophthalmic lens precursor.   32. A method of manufacturing an ophthalmic lens comprising processing the lens precursor of claim 31 to stabilize at least a portion of the second fluid surface.   The processing further comprises solidifying at least a portion of the second fluid surface using actinic radiation to a crosslink density that is at least partially polymerized at or above the gel point. 35. The method of claim 32. An apparatus for performing a method for generating an instruction set for use in an ophthalmic lens precursor mold manufacturing tool comprising:
A processor;
A storage device for digital data;
Executable software stored on the digital data storage device and executable on demand, operating in conjunction with the processor,
Receiving digital data describing one or more optical aberrations associated with a wearer of the ophthalmic lens;
Receiving digital data describing at least one desired mechanical parameter of the ophthalmic lens;
Executable software for receiving input from an operator describing at least one phase feature of the lens precursor type substructure and generating the instruction set for use in the ophthalmic lens precursor type manufacturing tool And comprising
The ophthalmic lens precursor type manufacturing tool comprises a digital mirror device, and the instruction set is a DMD display including time-based instruction data points that can be used to control activation of the digital mirror device;
The executable software operates in conjunction with the processor to the device;
Receiving digital data including a design thickness map of at least a portion of the lens precursor mold or lens precursor;
Receiving digital data including a measured thickness of at least a portion of a lens precursor mold or lens precursor produced by the production tool;
Comparing the measured thickness with the design thickness map to determine compatibility with the desired design; and
An apparatus for generating an alternative instruction set for use in the ophthalmic lens precursor mold manufacturing tool .   35. The apparatus of claim 34, wherein the mechanical parameters include one or more of a base curve, a diameter, and a center thickness.   36. The apparatus of claim 35, wherein the optical aberration may include one or more of low order aberrations, intermediate aberrations, and high order aberrations.   The at least one feature includes a portion of the lens precursor mold that can be mathematically described by one or more of the height, length, width, shape, and position of the feature. Item 37. The apparatus according to Item 36.   36. The apparatus of claim 35, wherein the at least one feature includes a lens edge feature according to any one of claims 1-8.   39. The apparatus of claim 38, wherein the at least one feature includes a moat feature according to any one of claims 9-12.   40. The apparatus of claim 39, wherein the at least one feature comprises an exhaust channel feature according to any one of claims 13-16.   41. The apparatus of claim 40, wherein the at least one feature comprises a volumeometer feature according to any one of claims 17-26.   A plurality of feature portions are defined parametrically, and the parameter defining at least one lens feature portion is at least partially in one or more adjacent lens feature portions and the parameter defining a desired lens shape. 42. The apparatus of claim 41, wherein the apparatus is selected based on.   42. The apparatus of claim 41, wherein at least one feature comprises a stabilization zone feature or optical zone portion of the lens precursor type.

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